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7400 Series UPS Single Module and 1+1 Configuration: User Manual
7400 Series UPS Single Module and 1+1 Configuration: User Manual
Single Module
and
1+1 Configuration
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MEASUREMENTS ALARM EMERGENCY
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MEASUREMENTS ALARM EMERGENCY
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MEASUREMENTS ALARM EMERGENCY
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User Manual
IMPORTANT
This manual contains information concerning the installation, operation and maintenance of the
Liebert Series 7400 Uninterruptible Power System (UPS) for the Single Module and One plus
One Systems.
All relevant parts of the manual should be read prior to commencing installation.
The UPS must be commissioned by an engineer approved by the manufacturer (or his
agent) before being put into to service. Failure to observe this condition will invalidate any
implied warranty.
The Series 7400 UPS has been designed for Commercial/Industrial use only.
The Series 7400 UPS has not been designed for direct use in any life support applications.
If you encounter any problems with the procedures contained in this manual you should seek
immediate assistance from the Liebert Sales Office from whom the equipment was purchased.
Alternatively contact the manufacturer's Customer Support department at the address shown
below:
The manufacturer reserves the right to change the equipment design without notice.
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WARNING
This is a UPS for restricted sales distribution to informed partners with the appropriate
EMC technical competence. Installation restrictions or additional measures may be needed
to prevent disturbances (EMC Standard 50091-2).
When fitted with the above optional e.m.c. kits the following warning applies:
This is a class `A' UPS product. In a domestic environment this product
may cause radio interference in which case the user may be
required to take additional measures.
This equipment complies with the requirements of the EMC Directive 89/336/EEC
and the published technical standards.
Continued compliance requires installation in accordance with these instructions
and the use of manufacturer approved accessories only.
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Safety Precautions
WARNING
THIS UPS DOES NOT INCORPORATE AUTOMATIC BACKFEED PROTECTION. A
WARNING LABEL MUST BE FITTED TO ALL EXTERNAL PRIMARY POWER
ISOLATORS STATING:
ISOLATE THE UNINTERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS
CIRCUIT.
General
In common with other types of high power equipment, dangerous voltages are present within the UPS
and battery enclosure. The risk of contact with these voltages is minimised as the live component parts
are housed behind a hinged, lockable door. Further internal safety screens make the equipment
protected to IP20 standards. No risk exists to any personnel when operating the equipment in the
normal manner, following the recommended operating procedures.
All equipment maintenance and servicing procedures involve internal access and should be carried out
only by trained personnel.
Batteries
Battery manufacturers supply details of the necessary precautions to be observed when
working on, or in the vicinity of, a large bank of battery cells. These precautions should be
followed implicitly at all times.
Particular attention should be paid to the recommendations concerning local environmental
conditions and the provision of protective clothing, first aid and fire-fighting facilities.
Test Equipment
When the battery is under charge it is earth-referenced about its mid-point e.g. if the battery
is being charged at 446 V the battery extremities will be at +223V and -223V with respect to
neutral (earth). When using mains-powered test equipment such as oscilloscopes in the UPS
high voltage area, always use a differential mode of operation to avoid the need to
disconnect the oscilloscope frame earth.
Personnel
When working inside the UPS (trained personnel only) it is recommended that protection be
worn to prevent eye damage, should an electrical arc be struck by mishandling or severe
electrical fault.
Some of the power components are very heavy. If their removal is necessary ensure that
sufficient manpower is available, otherwise use adequate mechanical handling
equipment.When working in the general area of the UPS where high voltages are present, a
second person should be standing-by to assist and summon help in case of accident.
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Table of Contents
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1.1 Introduction
The 7400 Series uninterruptible power supply (UPS) system is connected
between a critical load, such as a computer, and its three phase mains
power supply. Being designed to furnish a well regulated 3 phase output
power supply under all rated load and input supply conditions, the
system offers the user the following advantages:-
Increased power quality:
The UPS has its own internal voltage and frequency regulator circuits
which ensure that its output is maintained within close tolerances
independent of voltage and frequency variations on the mains power
lines.
Increased noise rejection:
By rectifying the input a.c. power to d.c. power, and then converting it
back to a.c., any electrical noise present on the input mains supply line is
effectively isolated from the UPS output, therefore the critical load sees
only clean power.
Power blackout protection:
If the mains power fails, the UPS continues to power the critical load
from its battery source, leaving the load immune from power
disturbances.
6 pulse Rectifier
The UPS basically operates as an AC-DC-AC converter (see figure 1-1).
The first conversion stage (from a.c. to d.c.) uses a 3 phase, fully-
controlled SCR bridge rectifier to convert the incoming mains supply
into a regulated 446 V d.c. busbar for a 400 V a.c. input (or 432 V d.c.
for a 380 V a.c. input or 459 Vd.c. for a 415V a.c. input).
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Bypass
Supply
STATIC
RECTIFIER INVERTER
SWITCH
Mains UPS
Supply Output
Supply
BATTERY
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12 Pulse Rectifier
The UPS basically operates as an a.c.-d.c.-a.c. converter (see figure 1-1).
The first conversion stage (from a.c. to d.c.) uses a 3 phase 12 pulse (2 x
6 pulse), fully-controlled SCR bridge rectifier system to convert the
incoming mains supply into a regulated d.c. busbar (432V d.c. for a
380V a.c. input; 446V d.c. for a 400V a.c. input or 459V d.c. for a 415V
a.c. input).
The input a.c. supply is applied (a) directly into a six pulse rectifier and
(b) via a 30° phase shift transformer into a second six pulse rectifier (see
figure 1-2). This phase shifting results in less distortion of the alternating
Mains Rectifier DC
Inductor Inductor
Supply bridges
L2
L1
To DC
Phase Busbar
displacement
transformer
AT1 Rectifier
bridges
12 Pulse
(2 x 6 pulse)
Rectifier system
Inverter
The d.c. busbar produced by the rectifier provides both battery charging
power and power to the inverter section-which uses the latest IGBT
switched pulse width modulation (PWM) design and provides the second
conversion phase; i.e. reconverting the d.c. busbar voltage back into an
a.c. voltage waveform.
During normal operation both the rectifier and inverter sections are
active and provide regulated load power whilst simultaneously float
charging the battery. In the event of a mains power failure, the rectifier
becomes inoperative and the inverter is powered solely from the battery.
Critical load power is maintained under these conditions until the battery
is fully discharged, whereupon the UPS shuts down. The end of battery
discharge is assumed when the battery voltage falls to 320 Vd.c. for a
system with a 380V a.c. input supply, 330V d.c. with a 400V a.c. input
supply and 340V d.c. with a 415V a.c. input supply.
The period for which the load can be maintained following a mains
power failure is known as the system’s ‘Autonomy Time’ and is
dependent upon both the battery A/Hr capacity and the applied
percentage load. It is usual in larger installations to provide an
alternative UPS input power source from a standby generator when the
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mains supply fails. Once such a generator has been brought on-line, and
the UPS input power has been re-established, the batteries
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1.2.2 Bypass supplies The circuit block annotated ‘Static Switch’ in figure 1-3 contains an
electronically controlled switching circuit which enables the critical load
to be connected either to the inverter output or to a bypass power source
via the ‘static bypass line’. Normally, the load is connected to the
inverter; but in the event of a UPS overload, or inverter failure, it is
automatically transferred to the static bypass line due to the static switch
action.
To provide a clean (no-break) load transfer between the inverter output
and static bypass line, the inverter output and bypass supply must be
fully synchronised during normal operating conditions. This is achieved
through the inverter control electronics which make the inverter
frequency track that of the static bypass supply-provided that the bypass
remains within an acceptable frequency window. The synchronising
window is pre-selected to 2% of nominal frequency, giving an acceptable
frequency window of ±1Hz.
An [INVERTER UNSYNCHRONIZED] warning message is displayed on the
operator control panel when the inverter and bypass supplies are not
synchronized.
A second, manually controlled, ‘maintenance bypass’ supply is also
incorporated into the UPS design. Its purpose is to enable the critical
load to be powered from the mains (bypass) supply while the UPS is shut
down for maintenance or troubleshooting.
Note:- The load is unprotected against mains power supply aberrations or
failure when it is connected to either the static bypass or maintenance
bypass supply.
1.2.3 UPS Power Switch
Configuration The power switch locations in the various 7400 models are shown in
Figure 1-4.Figure 1-3 illustrates the 7400 series UPS module power
switches in what is known as a “Split Bypass” configuration. This is the
standard configuration for all models in the 7400 range.
In the “Split Bypass” configuration the static bypass line is switched by a
separate isolator to a dedicated ‘bypass’ power source which also feeds
the maintenance bypass line.
With the exception of the maintenance bypass isolator, all the isolators
shown must be closed during normal UPS operation.
Although it cannot be classified as a ‘power switch’, the reset switch may
be used as part of the UPS operating procedure. Fitted to the UPS Logic
Board, the reset switch is used by the operator to re-transfer the load to
the inverter following a detected overload or over temperature fault.
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Maintenance
Bypass Isolator
BATTERY
1.2.4 Battery circuit breaker The battery is connected to the d.c. Busbar through a circuit breaker
fitted inside the battery cabinet or located adjacent to the batteries where
a battery cabinet is not used. This circuit breaker is closed manually, but
it contains an undervoltage release coil which enables it to be tripped
from the UPS control electronics following certain detected faults. It also
has a magnetic trip facility for overload protection.
1.2.5 Battery Cabinet In the case of the 80kVA and 120kVA UPS models, the batteries
associated with the UPS are generally housed in a purpose-built cabinet
located along-side the main UPS equipment.
It is possible to install batteries of various types and capacity in the
cabinet to obtain the required autonomy characteristics.
The battery cabinet can be purchased in one of the following forms:
1. Complete installation comprising the battery cabinet, batteries and
circuit breaker.
2. Battery cabinet and circuit breaker only with no batteries.
3. Battery cabinet only with no batteries or circuit breaker.
1.2.6 Battery circuit breaker
For the larger units and as an alternative to the battery cabinets, a
box
battery circuit breaker can be provided in a custom built box. This
Battery Circuit Breaker Box is designed to be wall or rack mounted and
is connected between the UPS and Battery.
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I4 I3 I2 I1 I4 I3 I2 I1
I1 = Input Isolator
I2 = Static Bypass Isolator
I3 = Maintenance Bypass Isolator (with padlock)
I4 = Output Isolator
I4 I1
I3
I4 I3 I2 I1
I2
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1.3.1 Redundant vs In a non-redundant module configuration, the system is sized such that
Non-Redundant both UPS modules are required to feed the potential load, and if one of
configuration the two modules develops a fault, or is for some reason shut down, the
other module automatically shuts down also.
Note: In such an event the load is transferred to an unprocessed bypass
supply -as described later.
In a redundant module configuration the system is sized such that the
potential load can be provided by just one of the two modules. Under
normal circumstances both modules are operational and share the load
current equally; but if one module develops a fault, or is shut down, the
second module is able to take over the full load demand and continue to
provide it with processed, backed-up power. The advantages of a
redundant system over a non-redundant system in terms of overall system
reliability are self evident.
Changing a one-plus-one system’s configuration between redundant and
non-redundant is quite straightforward, being carried out by
configuration links on the circuit board which governs the modules’
parallel control operation.
1.3.2 One-Plus-One Parallel When two of the standard 7400 modules just described are connected
Control together to form a one-plus-one system, each module is fitted with an
additional circuit board which allows the two modules to communicate
with each other. Communication takes place via a single ribbon cable
connected between the modules as illustrated in figure 1-5.
The inter-module parallel control responsibilities are complex but can be
summarised as follows:
Synchronisation:
As the outputs from both UPS modules are connected together to provide
a single load supply, it is imperative that the inverters are fully
synchronised both in frequency and phase. This is achieved by digitally
locking the two inverter control oscillators. Similarly, as has already
been mentioned, it is necessary for the inverters to be synchronised to the
bypass supply to enable a "no-break" transfer to be achieved when the
static switch transfers the load to the bypass supply. The inverter control
oscillators are therefore not only locked together but are also made to
track the bypass frequency.
Current sharing:
The parallel control circuit compares the module’s output current with
that of its partner and is thereby able to effect current sharing between
the modules by making fine adjustments of an individual module’s
output voltage.
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Redundancy configuration:
A link in the parallel control logic determines whether the one-plus-one
system operates in a "redundant" or "non-redundant" configuration.
If a non-redundant mode is selected the two static switch sections are
effectively locked together in that both static switches are turned off or
on by a single control signal. Thus if one module develops a fault, when
running, its static switch control logic will transfer its output from the
inverter to the static bypass line and simultaneously send a signal to the
static switch control logic in the second module to do likewise.
This does not happen if the system is configured as a redundant system,
in which case the second module is allowed to continue supplying the
load from its inverter when the first module trips its inverter off line.
Reverse current:
A reverse current monitor circuit detects current flowing into, rather than
out of, the module’s output terminals. Such a condition can arise if a
module develops an internal power fault or if for some reason the two
modules become unbalanced, and is liable to further damage the module
and also degrade the load supply. If a reverse current is detected the
inverter on the affected module is immediately shut down and
(depending on the system redundancy configuration) the load is
transferred to the bypass supply "Non-Redundant system", or remains on
the good inverter "Redundant system".
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Mains STATIC
RECTIFIER INVERTER SWITCH
Supply
BATTERY
UPS
BATTERY Output
Supply
Mains STATIC
RECTIFIER INVERTER SWITCH
Supply
1.3.3 Common battery The illustration in figure 1-5 shows a dedicated battery installation for each
module; however, it is possible to fit an option kit which allows the two
modules in a one-plus-one system to share a common battery. Such an
installation is shown in figure 1-6 overleaf.
Note: the "Common battery" configuration is possible with 6 pulse
rectifiers only, not with 12 pulse rectifiers.
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STATIC
RECTIFIER INVERTER SWITCH
Main
Supply
1+1 Parallel Control
Control
BATTERY Logic
UPS
Output
Supply
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1.4.1 Mimic indications Six leds are mounted on a single line diagram to represent the various
UPS power paths. These leds, which
are annotated in figure 1-8, show the current UPS operational status and
should be interpreted as detailed below.
LS1 - Input supply OK / Rectifier operative:
This led illuminates when the
input isolator (I1) is closed, the
input supply is within 20% of
nominal voltage, and the LS3
rectifier is operative.
LS2 - Battery volts OK: This LS5
led illuminates when the
battery circuit breaker is closed
and the battery voltage is
within the UPS operating range
(320V - 490V nominal).
LS3 - bypass supply OK: This
led illuminates when the static
LS1 LS2 LS4 LS6
bypass supply is within ±10%
of its nominal voltage.
LS4 - Inverter output OK: Figure 1-1 . Mimic panel
This led illuminates when the
inverter is operating and its output is within a preset (±10%) acceptable
voltage window.
LS5 - Load on bypass
This led illuminates when the output isolator is closed and the load is
connected to the bypass supply via the static switch.
LS6 - Load on inverter:
This led illuminates when the output isolator is closed and the load is
connected to the inverter via the static switch.
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1.4.2 Control switches Seven tactile switches are located on the Operator Panel, together with
an emergency stop pushbutton which is fitted with a safety cover to
prevent inadvertent operation.
S1
S2 S3 S4 LS7 S5 S6 S7 LS8 S8
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2.1 Introduction
The UPS can be considered to be in one of three operating conditions:
• Shutdown - All power isolators and circuit breakers open - no
load power.
• On Maintenance Bypass - UPS shut down but the load connected
to the unprotected mains via the Maintenance Bypass Supply line.
• Normal operation - All relevant power isolators and circuit
breakers closed, the load is powered by the UPS.
This chapter contains detailed instructions to enable you to switch
between these three conditions.
2.1.1 General notes Note 1: All the user controls and indicators mentioned in these
procedures are identified in chapter 1 (figures 1-3, 1-4, 1-7, 1-8 and 1-9).
Note 2: The audible alarm may annunciate at various points in these
procedures. It can be cancelled at any time by pressing the `Alarm Reset'
pushbutton.
Note 3: The 7400 series UPS incorporates an optional automatic boost
charge facility which can be used in systems containing non-sealed lead-
acid batteries. If this type of battery is used in your installation you may
notice that the battery charger voltage will be greater than its normal
value when the mains supply returns from a prolonged outage. The
revised voltage will be 460V d.c. for a 380V a.c. system, 475V d.c. for a
400V a.c. system and 490V d.c. for a 415V a.c system. This is the
normal response of the boost charge facility: the charger voltage should
return to normal after a few hours.
The difference in the system response concerns the point at which the
load is transferred between the bypass and uninterruptible (i.e. inverter)
supplies and is summarised below:
Starting:
2.2.1 Redundant module When starting a redundant module system the load is transferred from
system the bypass to the inverter of the first module as soon as the first module
is started and its inverter is brought on line. When the second module is
started its static bypass line is totally inhibited due to the first module
being on line, and the second module will not be connected to the load
until its inverter is operational and fully synchronised with the first
module.
Stopping:
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load will be fully maintained by the inverter of the second module.
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When shutting down the second module, the static bypass lines of both
modules will be turned on as soon as its inverter is stopped. That is, both
modules will provide load power through their paralleled bypass lines.
Starting:
2.2.2 Non-Redundant
In a Non-Redundant module system both modules must be running
module system
before the load is transferred to their paralleled inverters. Therefore,
when the first module is started, the load will remain connected to its
static bypass line while waiting for the second module to synchronise.
Stopping:
The load will be transferred to the static bypass lines in both modules
simultaneously as soon as the inverter stops in the first module to be shut
down.
4. Press the battery metering selector switch [B]: The display should indicate a positive (+) battery
charging current.
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How to turn off the system but continue to provide load power through the
maintenance bypass
This procedure should be followed if the UPS is to be powered-down while continuing to supply the load through the
maintenance bypass line. Note that during this procedure the load will be unprotected against mains supply disturbances once
the inverter(s) has been switched off.
WARNING
Wait at least 2 minutes for the d.c. capacitors to discharge.
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This procedure should be followed only if the UPS AND LOAD are to be completely powered down.
IMPORTANT
The Maintenance Bypass Isolator may be operated at any time
when the UPS is powered down to connect/disconnect the load
to the raw maintenance bypass supply if required.
Emergency stop
The emergency stop pushbutton is located behind a hinged safety shield to prevent
inadvertent operation. When this switch is pressed modules are electronically shut down and
battery circuit breakers are tripped. Power is removed from the critical load,
but pressing the emergency stop pushbutton will not remove the modules' input mains
supply unless an external contactor, controlled via the emergency stop pushbutton auxiliaries,
is fitted in the mains supply line..
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3.1 Introduction
WARNING
Do not apply electrical power to the UPS equipment before the arrival of the
commissioning engineer.
WARNING
The UPS equipment should be installed by a qualified engineer in accordance with the
information contained in this chapter and the drawing package shipped inside the
UPS cabinet.
WARNING
Battery hazards
Special care should be taken when working with the batteries associated with this
equipment. When connected together, the battery terminal voltage will exceed 400
Vd.c. and is potentially lethal.
Eye protection should be worn to prevent injury from accidental electrical arcs.Remove
rings , watches and all metal objects.
Only use tools with insulated handles.
Wear rubber gloves.
If a battery leaks electrolyte, or is otherwise physically damaged,
it should be placed in a container resistant to sulphuric acid and
disposed of in accordance with local regulations.
If electrolyte comes into contact with the skin the affected area
should be washed immediately.
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The UPS cabinets can be moved by fork lift or crane. Fork lift apertures
3.1.1 Equipment positioning
are provided in the sides of the base plate and are accessible after
and environmental
removing blanking covers fitted to the side panel ventilation grills. Roof-
considerations
mounted eye-bolts are fitted to enable the cabinet to be crane-handled.
These can be removed once the equipment has been finally positioned.
Note: In a 1 + 1 system the models should be positioned adjacent to each
other.
WARNING
Ensure that the UPS weight is within the designated S.W.L. of any handling equipment.
See the UPS specification for weight details.
Do not move the battery cabinet with the batteries fitted..
The 300kVA and 400 kVA UPS modules are split into two cabinets, a
Main Inverter cabinet and a Rectifier/Static Bypass cabinet, to allow
easier transportation and positioning. Once finally positioned, the two
cabinets have to be bolted together and the interlinking power and
control cable connections made. It is therefore necessary to observe
cabinet A & B positioning (see figures 3-5 and 3-6 ).
The UPS module should be located in a cool, dry, clean-air environment
with adequate ventilation to keep the ambient temperature within the
specified operating range. If necessary, a system of extractor fans should
be installed to aid cooling-air flow, and a suitable air filtration system
used where the UPS is to operate in a dirty environment.
Cables
All control cables whether screened or not, should be run, separate from
the power cables, in metal conduits or metal ducts which are electrically
bonded to the metalwork of the cabinets to which they are connected.
Clearances
To allow adequate cooling air flow, you should position the equipment
with the following space around the back and sides.
80kVA-120 kVA Models 100mm minimum required in all cases.
200/300/400 kVA Models 300mm minimum required in all cases.
The UPS modules do not require back-access for maintenance servicing;
but, where space permits, a clearance of approximately 4 feet (1.2
metres) will ease access to some component parts. Clearance around the
front of the equipment should be sufficient to enable free passage of
personnel with the doors fully opened.
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3.1.2 Raised floor If the equipment is to be located on a raised floor it should be mounted
installation on a pedestal suitably designed to accept the equipment point loading.
The installation diagrams in the back of this manual identify the location
of the holes in the base plate through which the equipment can be bolted
to the floor.
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7400 Series UPS User Manual Chapter 3 - Installation Procedure
Single Module and One plus One Systems Preliminary Checks
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2. Remove any packaging debris then visually examine the UPS and
battery equipment for transit damage, both internally and externally.
Report any such damage to the shipper immediately.
3. Verify that the shipment is complete e.g. that the battery contains
the correct number of cells etc. Report any discrepancy immediately.
4. When you are satisfied that the equipment is complete and in good
condition move it to its proposed final position.
Note: If ‘side’ cable entry is to be used (see below) ensure that the
blanking plates are removed before finally fixing the cabinets in
position.
Caution
Ensure the stabilising bar fitted to the output transformer T1 is removed before
proceeding with the installation.
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Caution
Ensure loose cables are not trapped between the two cabinet frames.
1. Align the Rectifier/Static switch and Inverter Cabinets and bolt them
together through the holes provided.
2. Open the doors to the Inverter cabinet and remove the lower
protective cover to gain access to the a.c. busbars R, S, T & N from
the output transformer T1.
3. Locate the four a.c. busbars from the Output Isolator numbered 7(R),
8(S), 9(T) and 10(N) in the Rectifier/Static Switch cabinet and the
linking straps connected to them. Take the free end of the linking
straps and connect them to the Inverter cabinet a.c. busbars ensuring
correct phase connection as illustrated in figure 3-6.
5. Open the upper inner left hand protective door of the inverter cabinet
to gain access to the d.c. busbars.
6. Open the doors to the Rectifier/Static Switch cabinet and open the
inner upper right hand door to gain access to the d.c. busbars.
7. Using the two angled copper busbar links provided, connect the
Rectifier/Static Switch cabinet d.c. busbar to the Inverter Cabinet d.c.
busbar as illustrated in figure 3-6.
8. Locate the flat cable assembly FC17 from CN8 on the Inverter Logic
board in the Inverter cabinet and secure to the end panel, in the
position illustrated in figure 3-6.
9. Locate the flat cable assembly FC17 from CN2 on the UPS Logic
board in the Rectifier/Static Switch cabinet and connect to cable
assembly FC17 secured above.
10. Locate wires 27, 28, 29, 30, 31, 32, 33, 98 & 99 terminated in
connector CN4 and wires 7, 8, 9 & 10 terminated in connector CN5
in the Inverter cabinet and secure the connectors into cabinet end
panel in the positions illustrated in figure 3-6.
11. Locate the Rectifier/Static Switch cabinet cable assemblies from the
Interface board which terminate in connectors CN4 and CN5 and
connect to CN4 and CN5 secured above.
12. Close the inner protective doors and outer doors to both cabinets.
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WARNING
Before cabling-up the UPS, ensure that you are aware of the location and operation of
the external isolators that connect the UPS input/bypass supply to the mains
distribution panel.
Check that these supplies are electrically isolated, and post any necessary warning signs
to prevent their inadvertent operation.
3.4.1 Cable entry Cables can enter the smaller UPS modules and battery cabinet either
from below or through either side. Side entry is made possible by
removing blanking pieces fitted in the side ventilation grills to reveal the
cable entry holes. This cable entry method allows the equipment to be
positioned on a solid floor without the need for cable trenching and also
allows cables to pass from one module to the other when positioned side-
by-side.
The maximum current ratings for the power cables are given in table 3-1.
3.4.2 Cable rating The neutral cable (bypass and output) should be sized at up to 1.5 times
the phase current to take into account the possible presence of 3rd
armonic currents due to single phase "computer loads".
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3.4.3 Cable connections Power cables are connected either directly to their respective circuit
breakers, or to busbars which are themselves connected to the circuit
breakers see figures 3-8 to 3-12.
Note: If the installation includes the use of optional Input Filter Cabinets
refer immediately to the Options Chapter, Where these cabinets are fully
described. The inclusion of these cabinets in the system affects the
method of connecting the UPS power cables given below.
3.4.4 Safety earth The safety earth busbars are located near the input and output power
supply connections as shown in the
following diagrams. The safety cable must be connected to the earth
busbar bonded to each module cabinet.
All cabinets and cable trunking should be earthed in accordance with
local regulations.
WARNING
FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN
ELECTRIC SHOCK HAZARD TO PERSONNEL, OR THE RISK OF FIRE, SHOULD
AN EARTH FAULT OCCUR.
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1. Verify that the UPS equipment is totally isolated from its external
power source and all the UPS isolators are open.
2. On each module, connect the input supply cables between the mains
distribution panel and the UPS input mains terminals. Check that
links are fitted between input mains bus bars and bypass supply bus
bars (U1 - U3; V1 - V3; W1 - W3).
ENSURE CORRECT PHASE ROTATION.
4. On a Single module connect the UPS output cables between the UPS
and the load distribution panel.
6. On each module, connect the battery cables between the UPS battery
terminals and its associated battery circuit breaker see figures 3-13
to 3-17. As a safety precaution remove the battery fuse in the module
until the arrival of the commissioning engineer.
OBSERVE THE BATTERY CABLE POLARITY.
WARNING
Do not close the battery circuit breaker before the equipment has been commissioned
7. Connect the safety earth and any necessary bonding earth cables to
the copper earth busbar located on the floor of the equipment below
the power connections.
Note:- The earthing and neutral bonding arrangement must be in
accordance with local and national codes of practice.
Control Cables
8. Connect the battery circuit breaker control cables between the UPS
auxiliary terminal block and battery circuit breaker controller board
as shown in figures 3-13 to 3-17.
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Caution
Module 1 Module 2
CN3 CN3
CN2 CN2
CN1 CN1
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Figure 3-5 . Cable connections for 6 & 12 Pulse 300/400 kVA modules
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WARNING
Only qualified personnel should install or service batteries.
A battery can present a risk of electric shock or burn from high short circuit currents.
Eye protection should be worn to prevent injury from accidental electrical arcs.
Remove rings , watches and all metal objects.
Only use tools with insulated handles.
Wear rubber gloves.
If a battery leaks electrolyte, or is otherwise physically damaged, it should be placed in a
container resistant to sulphuric acid and disposed of in accordance with local regulations.
If electrolyte comes into contact with the skin the affected area should be washed
immediately.
Batteries must be disposed of according to local environmental laws.
Due to the inverter design the d.c. bus bar voltage level is dependent on the
system output a.c. voltage. Therefore, the number of battery blocks required
will differ according to the system requirements, as shown below:
380V a.c. system requires 432V d.c. bus bar = 32 battery blocks / 12 V (192
cells).
400V a.c. system requires 446V d.c. bus bar = 33 battery blocks / 12 V (198
cells).
415V a.c. system requires 459V d.c. bus bar = 34 battery blocks / 12 V (204
cells).
The batteries associated with the 80 kVA and 120 kVA UPS can be
contained in a purpose-built battery cabinet ( part number 5320024I
{860mm wide, 250 A circuit breaker}) which sits along side the main UPS
equipment. Sealed, maintenance-free batteries are normally used in this type
of installation.
Where battery racks are used, they should be sited and assembled in
accordance with the battery manufacturer’s recommendations. In general,
batteries require a well ventilated, clean and dry environment at reasonable
temperatures to obtain efficient battery operation.
Battery manufacturers’ literature provides detailed safety measures to be
observed when employing large battery banks and these should be studied
and the proposed battery installation checked to verify compliance with the
appropriate recommendations.
In general a minimum space of 10 mm must be left on all vertical sides of
the battery block. A minimum clearance of 20 mm should be allowed
between the cell surface and any walls. A clearance of 150 mm should be
allowed between the top of the cells and the underside of the shelf above
(this is necessary to for monitoring and servicing the cells). All metal racks
and cabinets must be earthed. All live cell connections must be shrouded.
The batteries are connected to the UPS through a circuit breaker which is
manually closed and electronically tripped via the UPS control circuitry. If
the batteries are cabinet-mounted this circuit breaker is fitted within the
cabinet; however, if the batteries are rack-mounted or otherwise located
remote to the main UPS cabinet then the battery circuit breaker must be
mounted as near as possible to the batteries themselves, and the power and
control cables connected to the UPS using the most direct route possible.
Liebert offer a purpose designed remote battery circuit breaker box,
containing the circuit breaker and its necessary control board, as a standard
option kit. The battery cabinet or circuit breaker box must be bonded to the
UPS cabinet.
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3.5.1 860 mm cabinet The 860 mm cabinet with a 250 Amp circuit breaker and extension
(250 Amp circuit cabinets are designed for use with the Series 7400 80-120 kVA UPS.
breaker)
The 860mm battery battery cabinet autonomy time can be extended by
attaching a 320mm wide extension cabinet part N°5320025J to the main
cabinet.
All cabinets are secured and bonded together using the bolts supplied
and the holes proved in the cabinet side struts.
A typical battery layout for a single cabinet is shown in figure 3-13, this
can be extended by using extension cabinets attached to the basic unit.
Each extension cabinet is supplied without side covers, as the covers
from the basic unit are then used. This side access allows batteries to be
positioned from either the front or side.
As many different battery combinations can be used only the connections
for the basic unit have been shown in figure 3-13, additional battery
strings can be added and would be connected in parallel.
The battery cabinets are designed to hold between 32 and 34 batteries on
4 levels, free standing on adjustable rails. Nine batteries can be fitted to
the 3 upper levels with up to seven batteries on the lower level. The rails
are adjustable giving a maximum battery width of 176mm and a
maximum depth of 270mm, this allows batteries to be positioned as
shown or turned through 90°. The rails can also be removed or re-
positioned to accommodate batteries of different sizes.
Figure 3-14 shows an alternative arrangement to that above. In this
example larger capacity batteries are used. As can be seen, the rails have
been adjusted and removed to accommodate the larger battery of which
only sixteen can be fitted within the cabinet. The other sixteen batteries
(needed to maintain a 432 V d.c. bus bar) are arranged within an
extended battery cabinet and connected in series to the main cabinet
batteries. Further pairs of extended battery cabinets can be added in
parallel.
The basic cabinet is supplied with the battery circuit breaker and
interface board. Connection to the UPS is shown in figure 3-13.
Due to the flexibility of the type and size of cells that can be used in this
installation it would be impracticable to provide specific installation
instructions. However as a general guide:-
Always install the batteries starting from the bottom and work
upwards.
Leave the end links marked (B) see figure 3-13 until the last
connection on each level.
After each connection is made fit the insulation shroud for that
terminal into position.
As an added safety precaution we suggest that link (A) see figure 3-
13 is left disconnected until all batteries are fitted. Once all the
batteries are fitted connect link (A).
Please refer to the battery manufacturers instructions and the drawings
supplied with the module for safety and specific installation instructions.
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Figure 3-1 . 860mm Battery cabinet Typical battery layout and connection delail
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A battery circuit breaker box houses the battery circuit breaker and its controller
3.5.2 Battery circuit breaker
board and is used to connect the battery to the UPS in installations where the
boxes
batteries are not contained in the standard battery cabinet.
Several ‘boxes’, of various current ratings, are available and are similar in their
design and content. These are listed below:
• 250 Amp C/B Part No4641007H for use with 80 kVA models.
• 400 Amp C/B Part No4641008I for use with 120 kVA model.
• 630 Amp C/B Part No4641009D for use with 200 kVA model.
• 800 Amp C/B Part No4641011L for use with 300 kVA model.
• 1000 Amp C/B Part No4641012M for use with 400 kVA model.
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As a safety precaution, remove the battery fuse in the UPS before making the
battery circuit breaker power connections.
To Barrery
-ve
+ve
Battery C.B
BATTERY Controller Bd
CIRCUIT (4520063 P)
BREAKER BOX
+ + - -
+ve
-ve
Figure 3-2 . Battery C/B box connections200 kVA UPS
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+ve
-ve
To Battery
+ve
-ve
Battery C.B
Controller
Bd (4520063P)
- - + +
+ve
-ve
Figure 3-3 . Battery C/B box connections for 300kVA and 400 kVA Modules
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To initialise the system and insert the nominal battery capacity, press push buttom
‘B’ then carry out the following procedure:
1. On the PCB 4550001 B move the link on SH7 to position on pins 2-3.
2. On the display panel press push buttons ‘f’, ‘B’ and ((*)).
3. Check the display reads:
CN3
LED 1
TM2
SH1 SH4
3
1 3 1 3
SH7 CN4
1
1 3
I1 SH9
TM1
CN2
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4.1.1 AS400 Interface Board Two female D-type connectors are provided on the Interface Board to
outputs enable the above signals to be connected to the AS400 computer. One
connector, CN1, has 9 pins and the other, CN2, has 15. Figure 4-1
provides pin-out details for these connectors.
Note: Use one connector only -i.e.
don't use both connectors simultaneously.
Note: When using the above contacts for remote alarm annunciation, the
power supply for the remote indicators must be provided from an external
power source. Under no circumstances should the UPS internal low voltage
supplies be used for this purpose.
4.1.2 Remote control inputs
The Interface Board has facilities to accept two remote control inputs, as
shown in figure 4-1. One remote input allows the inverter to be shut
down (transferring the load to the bypass supply) and the other enables
the inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the
generator frequency is unstable.
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Notes:
1.All relays operate on Event
2. M1 pin numbering starts physically from
Bottom.. Pin Numbers are correct.
Figure 4-1 . AS400 Interface Board outputs Single and 1+1 Modules
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4.2.1 Remote control inputs The Interface Board has facilities to accept two remote control inputs, as
shown in figure 4-2. One remote input allows the inverter to be shut
down (transferring the load to the bypass supply) and the other enables
the inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the
generator frequency is unstable.
The external control signals (12V dc or ac) should be connected to
terminal block M1 as shown in figure 4-2. Once again, the voltage
applied to these terminals must be generated by an external power source
and not taken from the UPS internal low voltage supplies.
4.2.2 Calibration When fitting the AS400 interface board to the 7400 series, ensure that
link SH-1 is in position 1-2.
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Note: When using the contacts for remote alarm annunciation, the power
supply for the remote indicators must be provided from an external
power source. Under no circumstances should the UPS internal low
voltage supplies be used for this purpose.
4.3.2 Remote control inputs The board has facilities to accept two remote control inputs, as shown in
figure 4-3. One remote input allows the inverter to be shut down
(transferring the load to the bypass supply) and the other enables the
inverter synchronisation feature to be inhibited. The inverter
synchronisation inhibit feature is most often used if the UPS is powered
from a standby generator when the input mains supply fails and the
generator frequency is unstable.
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Table 4-1
An audible warning accompanies any of the above alarm conditions.
This is, however, subject to a short time delay when activated in
conjunction with the ‘Utility Failure’and ‘Bypass ON’alarms, to prevent
the warning being activated by transient conditions. Pressing the
‘reset’pushbutton cancels the audible warning but the alarm indications
remain until the condition is rectified.
Alarm connections
A 9 pin D-type connector with solder points is provided with the RAM.
This connector fits into the 9 pin socket on the top of the RAM and
should be cabled to the AS400 Interface Board (4590041B or
4590045F), fitted to the UPS, using 9 core, 0.22mm. (minimum) cable as
shown.
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The Remote Alarm and Control Panel, which can be mounted either
horizontally or vertically, contains a mains driven power supply for
alarm LED annunciation. An audible warning accompanies any of the
alarm indications after a short time delay, this can be silenced by the
operator.
The following list gives an interpretation of the controls and alarm
facilities:
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Alarm connections
Alarm connections from the UPS modules are provided by connectors
M1 (5 way terminal block), M2 (15 way terminal block) and M3 (15 way
terminal block) on the Output Interface boards (4590044E), to CN1 (50
pin D-type connector) on the Remote Alarm and Control panel (4305002
A).
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Figure 4-1 . UPS System connection and identification of the control and
indication of the Remote Alarms and Control Panel
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Interface board Pt. No. 4305002 A Interface board Pt. No. 4305002 A
Pt. No. 4590044 E Pt. No. 4590044 E
M3 Terminals CN1 Pins M3 Terminals CN1 Pins
15 15 15 10
14, 11, 8, 5, 2 29 14, 11, 8, 5, 2 24
12 33 12 28
9 17 9 12
6 31 6 26
3 14 3 9
M2 Terminals M2 Terminals
15 30 15 25
14, 11, 8, 5, 2 46 14, 11, 8, 5, 2 41
12 13 12 8
9 16 9 11
6 32 6 27
3 49 3 44
2 50 2 45
M1 Terminals M1 Terminals
5 47 5 42
4 48 4 43
Table 4-3
UPS module Interface board terminal connections to Remote alarm and control panel socket pins.
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Figure 4-2 . Interconnections between the UPS modules and the Remote Alarms and Control Panel
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4.6.1 Introduction The optional RS232 Communications Management Board takes existing
information available from the display
assembly, stores it and converts it into a customer usable form for display
either locally or remote to the UPS. It can be interrogated via a telephone-
modem system from a remote service centre and it can activate a remote
station in the event of an alarm to down-load the current status.
The remote terminal, as well as receiving information from the UPS, can
interrogate the system. It can do this in two ways:
1. Manual input from the keyboard will allow the operator to select any
one of the UPS on the system and request the current status.
2. The operator may select any or all the UPS from a list residing in the
computer and call automatically, overnight if necessary.
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2. Batteries:
these may be of any non-rechargeable type (alkaline, ‘environment-
friendly', etc.) as long as they are of the correct size (AAA).
4. Flat, 25-wire cable ending in two 25 pin connectors, one male and
one female, for UPS-PC connection.
6. Flat, 25-wire cable ending in two 25 pin connectors, one male and
one female, for local UPS- modem connection.
8. Flat, 25-wire cable ending in two 25 pin connectors, one male and
one female, for remote modem-PC connection.
Direct Connection
This type of connection requires items 1, 2, 3, and 4 from the above list.
It is possible to obtain data from a distance of upto 15 metres through the
EIA RS232E interface.
Complete Connection
Complete connection require the total resources of the above.
Full installation and operating instructions are supplied with the option.
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5th Harmonic Input Filter Single Module and One plus One Systems
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4.7.1 Introduction An optional input 5th harmonic filter can be added to the 6 pulse 7400
series UPS to improve the UPS input power factor and reduce the
amount of electrical noise reflected into the input three phase supply.
On units upto 200 kVA the filter components are contained in a purpose-
built cabinet which is positioned alongside the main UPS equipment and
connected in series with the UPS input supply. In the case of the 300/400
kVA models the input filter is located within the UPS as illustrated in
figure 4-12. The filter components are matched to the UPS capacity,
resulting in different part numbers for each system as follows:
Part No. Weight
80kVA filter cabinet 5331016 C 220kg.
120kVA filter cabinet 5331018 E 240
kg.200 kVA filter cabinet 5331020 G 280
kg.300 kVA filter (internal) 4641010 K N/A
400 kVA filter (internal) 4641013 N N/A
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Bypass Supply
Isolator 1 Bypass Supply
BATTERY
BATTERY
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CN8
+ve
-ve
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4.8.1 Introduction This modification kit is for use with 80 kVA 120 kVA and 200 kVA
models only.
As can be seen in figure 4-13 this kit comprises front, rear and top panels
which when assembled using the extension brackets and existing UPS
end panel, allows you to extend the UPS width by approximately
200mm. This then allows cable entry through the top aluminium panel. It
is necessary for the user to size and cut holes in the top panel for the
cables to be used.
CABLE TOP
ENTRY EXTENSION
Existing UPS
side panel
Existing UPS
side panel
FRONT VIEW SIDE VIEW
Extension bracket
Cable
securing
Rear
Front panel panel
UPS Cabinet
Figure 4-1 . Cable Top Entry Kit
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4.9.1 Introduction The 12 pulse option for the series 7400 UPS is normally factory fitted.
The power and control cable connections for all units are identical to
those given in chapter 3 of this manual. The 300/400 kVA units have the
option fitted into the existing cabinet. However, for 80, 120 and 200
kVA units with part numbers as indicated in the front of this manual, the
option can be fitted on site by a Liebert certified service engineer. The
option is fitted into a purpose designed cabinet that when bolted to the
side of the UPS cabinet extends the system width by 400mm. As with all
series 7400 bolt-on options, the mechanical connection is achieved by
removing the UPS cabinet side panel; the additional cabinet is then
bolted on to the UPS cabinet at the four corners; the side panel removed
from the UPS cabinet is then fitted to the additional cabinet side wall to
complete the system.
The details given in figure 4-15 refer to the 80kVA unit. The 120kVA
and 200 kVA units are identical except for the following identification
numbers:
WARNING
BEFORE STARTING INSTALLATION OF THIS OPTION ENSURE ALL EXTERNAL
ELECTRICAL POWER SUPPLIES ARE SWITCHED OFF AND MADE SAFE.
DISPLAY THE RELEVANT NOTICES. ENSURE THE BATTERIES ARE ISOLATED
FROM THE UPS. CARRY OUT VOLTAGE CHECKS ON ALL INPUT, OUTPUT AND
BATTERY CONNECTIONS..
1. Gain access to UPS interior, open upper hinged panel. Remove the
bus bar +ve and -ve connection links from between the rectifier
output and the d.c. bus bar.
2. Connect cable 88 from the option cabinet TC4 to the UPS rectifier
output +ve bus bar.
3. Connect cable 89 from the option cabinet L2 (term A1) to the UPS
rectifier output -ve bus bar.
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7. Connect flat cable FC22 from the option cabinet PCB 4590051L
(connector CN1) to the UPS PCB 4520073Z (connector CN9).
8. Connect flat cables FC19, FC20 and FC21 from the option cabinet
PCB 4612141 B (connectors CN1, CN2 and CN3) to the UPS PCB
4520073Z (connectors CN6, CN7 and CN8).
9. Connect wire No.80 from the option cabinet fan CN3 (1) to the UPS
fuse F12.
10. Connect wire No.82 from the option cabinet fan CN3(2) to the UPS
fuse N.
11. For UPS 200 kVA only: move wires No. 46/48 from terminal 4 to
terminal 2 of TA1 - TA2 in the UPS.
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4.10.1 Introduction This kit is intended for use in to any Series 7400 UPS fitted with the
appropriate Rectifier Logic Board (part no. 4520073Z). The kit provides
the following facilities:
p Battery temperature compensation:
With this feature fitted and enabled the nominal float voltage
supplied to the battery is adjusted so as to be inversely proportional
to the ambient battery cabinet/room temperature ( as monitored by a
remote temperature sensor ). This prevents the battery being over
charged at high ambient temperatures.
Example: - the d.c. float voltage is reduced by 1.5V d.c. per oC rise
in battery Temperature from 25oC to 35oC.
p Reduced input current limit:
This facility allows the UPS input current limit to be reduced to a
predetermined level. This may be necessary when running the UPS
on a standby generator. The system is activated by the closure of a
normally open contact. The input current limit can be reduced from
115% to 50% of nominal.
p Reduced battery current limit:
This facility allows the UPS battery current limit ( i.e. the magnitude
of the battery charging current) to be reduced to a preset value. This
may advisable if the battery cabinet/room ventilation system failed.
The system is activated by the closure of a normally open contact.
The battery current limit can be reduced from 100% to 10% of its
initial setting.
4.10.2 Installation Unpack the kit carefully and examine the parts for any signs of transit
damage . Check that the following items are included in the kit:
1 77000002 PCA Option board.
1 83696005 Temperature sensor kit.
4 49030060 Screws (M3 x 6).
Fit the supplied equipment as follows:
2. Locate onto the plastic stand-offs and secure the option board into
position as shown in figure 4-16 using the screws provided.
3. Fit links into position on the option board for the features required.
See table 1 for enabling link positions
4. Connect 10 way ribbon cable between PL1 on the option board and
connection CNx on the Rectifier Logic board following existing
cable routes.
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5. Chapter 5 - Maintenance
5.1 Introduction
This chapter contains the procedures necessary to effect general
maintenance of the UPS module and battery. Certain procedures entail
gaining internal access to the UPS, and should only be undertaken by a
competent engineer who is familiar with the operation and layout of the
equipment and understands the areas of potential hazard. If you have any
doubts concerning safety or the method of carrying out any procedure
then contact an approved service agent for assistance or advice. If the
locally approved agent is not known to you, then you should contact the
Customer Services & Support department at the address shown at the
front of this manual.The manufacturer offers customer training, at a
nominal fee, if required. Such training can range from a one-day operator
course to in-depth training on maintenance and troubleshooting lasting
several days, and can be carried out at the manufacturer’s plant or at the
customer premises.
1. Carry out a spot check of the operator control panel; ensuring that all
mimic LED indications are normal, all metered parameters are
normal and no warning or alarm messages are present on the display
panel.
4. Ensure that the ventilation grills around the UPS are unobstructed.
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5.3.2 Weekly checks Carry out the following checks from the mimic panel and log the results:
3. Measure and record the UPS output voltage on all three phases.
4. Measure and record the UPS output line currents. If these are
significantly different from the values previously logged then, if
possible, record the size, type and location of any additional load
connected to the UPS supply since the previous inspection. This type
of information could prove useful to the troubleshooting engineer
should a problem occur.
If any of the above indications differ greatly from the previously
logged values for no apparent reason then you should contact the
Customer Service & Support Department at the address given at the
front of this manual for advice.
3. Isolate the UPS input mains supply externally (also the bypass
supply if a split bypass system is in use) and isolate the battery.
4. Ensure that the UPS is totally powered down by checking for voltage
at the mains input terminals, battery connection terminals, and
output terminals (and bypass mains input terminals in a split bypass
configuration).
5. Gain full access to the UPS interior by opening its internal hinged
safety panel.
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Printed circuit boards - check the cleanliness and integrity of the circuit
boards and replace if any signs of deterioration are found.
9. Start the UPS and transfer the load to the inverter following the
appropriate operating procedure.
10. If possible, check the battery autonomy time by opening the input
isolator (I1) with the UPS on-load. Close the input isolator
immediately the dc busbar voltage falls within 5 volts of the battery
end of discharge voltage. (note For units operating at 380V a.c. the
end of battery discharge is assumed when the battery voltage falls to
320 Vd.c. For units operating at 400V a.c. the end of discharge
voltage is taken as 330 Vd.c. For units operating at 415V a.c. the
end of discharge voltage is taken as 340 Vd.c. At these voltages the
battery circuit breaker will trip and the load will power-down, unless
a split bypass system is in use whereupon the load will transfer to
bypass). Ensure that the available battery autonomy time meets the
installation specifications.
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6. Chapter 6 - Troubleshooting
WARNING
Some of the instructions in the charts at the end of this chapter involve checking internal
fuses. This should be undertaken (after the equipment has been shut down) only by a
trained electrician who is familiar with the layout and operation of the equipment and
fully conversant with the areas of potential hazard .
6.1.2 General Troubleshooting should be carried out methodically using the following
Troubleshooting guidelines:
Procedure
Fault Identification
When first summoned to the scene of a UPS fault, your immediate action
should be to observe and record the displayed messages, mimic
indications, meter indications and the position of the UPS power isolator
switches. This should be completed before you touch any switch.
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Corrective Action
When all the indications have been noted, you should refer to the
following fault interpretation charts and carry out the actions detailed
against any led whose status is abnormal. If you are unsure as to how to
undertake the actions detailed - or if several led indications are abnormal
and you are unable to distinguish between the likely cause and affects -
then seek immediate assistance from an approved service agent.
Fault Reporting
Irrespective of whether fault rectification is successful or not, report the
fault occurrence to the nearest service agent - who will then forward the
details to the manufacturer. This type of customer feedback is an
important factor in maintaining high product reliability, and also
provides important data concerning the equipment field performance.
Caution
The following diagnostic charts are designed for 'first aid’troubleshooting only. If a
problem cannot be resolved by taking the actions given then fully trained assistance
should be sought immediately.
Do not under any circumstances make internal circuit adjustments or interfere with the
circuit boards in any other way.
LS3
LS5
LS4
LS1 LS2 LS6
Figure 6-1 . Mimic pannel
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Check that the bypass circuit breaker is closed, the supply is available and within
specification, and phase rotation is correct.
LS4 ON If this led is OFF it signifies that the inverter is not producing its correct output
voltage.
Check the following:
a) If [OVER TEMPERATURE] OR [OVERLOAD] alarm messages are
active then (after allowing the UPS to cool / checking that the load
current on the bypass line is not excessive) press the reset switch (PS1)
on the UPS Logic Board.
b) Press the Inverter ON pushbutton on the mimic display.
c) If the dc busbar is below 320V (330 Vdc for a 400V input supply and
340 Vdc for 415V input supply ) hen do checks as per LS1 above.
d) Check that slide switch I2 is closed on the UPS Logic Board.
e) If the inverter works OK when mains is available but not when mains is
unavailable then check the dc power supply fuses.
If the above checks prove unsatisfactory then seek qualified assistance.
LS5** OFF If this led is ON then it signifies that the load has been transferred to the static
bypass supply and the output circuit breaker is closed. This indication should be
mutually exclusive with LS6 described below - check out LS6 actions.
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DISPLAY INTERPRETATION
MESSAGES
EMERGENCY STOP This alarm indicates that the UPS was shut down by means of the local or remote (if
ALARM fitted) emergency stop pushbutton which of course is normally due to operator action
- investigate why the emergency stop pushbutton was pressed.
If the emergency stop pushbutton was not pressed then check the continuity of the
remote emergency stop line (if fitted), and if no remote emergency stop line is fitted
then check that a link is connected between terminals 4 and 5 of the UPS auxiliary
terminal block.
INVERTER OFF OR This alarm is active whenever the inverter is not producing its correct output voltage;
FAILED ALARM either because it has been switched OFF or due to an internal fault.
The alarm will accompany other alarms such as [OVERLOAD], [LOAD ON
BYPASS]
OVER TEMPERATURE Over temperature is sensed by a normally-close thermostat (90°C operating) fitted to
ALARM each inverter heat sink. If an over temperature condition arises, the audible alarm
will accompany this message - the inverter stops and load transfers to bypass after 3
minutes.
OVERLOAD The inverter overload has an inverse load/time characteristic - i.e. it will accept
ALARM 125% overload for 10 minutes and 150% for 60 seconds. If this characteristic is
exceeded then the load transfers to the bypass supply, the inverter stops and the
overload alarm annunciates. The [OVERLOAD] alarm will annunciate at soon as the
load exceeds 100% of the UPS rating, and the load will transfer to bypass some time
later -depending on the degree of overload present.
BATTERY CB OPEN or This is a status indication only. Note that if the UPS if operating with the battery
BATTERY FUSE FAIL circuit breaker open and the mains power fails then the UPS output will also fail
ALARM together with load power. Also check battery fuses.
OUTPUT CIRCUIT This is a status alarm. The output isolator must be selected ‘CLOSED’at all times
BREAKER OPEN ALARM except when operating on the maintenance bypass supply.
RECTIFIER OFF OR This alarm is active whenever the battery charger (rectifier) is not producing its
FAILED ALARM correct output voltage; due to either an input supply failure, an internal fault, or an
open input circuit breaker.
UPS ON This is a status warning that the load is being powered through the maintenance
MAINTENANCE BYPASS bypass line and is unprotected from mains supply abbreviations. Due to the fact that
WARNING the UPS power supplies are fed by the input circuit breaker, this message will
disappear if the input isolator is opened (and bypass isolator opened on a split bypass
system) while the load is on the maintenance supply.
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INVERTER This warns that the inverter is not synchronised with the bypass supply, which is
UNSYNCHRONIZED normally due to a problem with the bypass supply being outside an acceptable
WARNING frequency window. Do not switch OFF the inverter when this alarm is active or the
load will experience a 20 msecond power break.
BATTERY ON LOAD This is a status warning that the battery is discharging. It normally accompanies a
WARNING [MAINS FAILURE] or [RECTIFIER OFF OR FAILED] message.
MAINS FAILURE MAINS FAILURE. Or mains supply out of specified acceptable range. Do not switch
WARNING OFF the inverter while this indication is active or the load will lose its power.
BYPASS CB OPEN This is a status alarm. The bypass isolator must be closed at all times
ALARM
LOAD ON BYPASS This is a status warning that the load is being powered through the static bypass line
WARNING and is unprotected from mains supply aberrations.
Note: The dc busbar low voltage level is 330 Vdc for a 400V input
supply and 340 Vdc for 415V input supply.
The battery circuit breaker will open automatically if the dc voltage falls
below these levels.
Check the following:
b) DC busbar voltage - if not above 320V (330 Vdc for a 400V input
supply and 340 Vdc for 415V input supply ) then carry out checks as per
LS1 (mains failure) above. If the dc busbar voltage is greater than
320V(330 Vdc for a 400V input supply and 340 Vdc for 415V input
supply) but you are unable to close the battery circuit breaker then seek
qualified assistance.
c) If the dc busbar is below 320V (330 Vdc for a 400V input supply and
340 Vdc for 415V input supply) then do checks as per LS1 above.
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BATTERY CABINETS
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Undervoltage trip coil rating all units 110Vdc (6,7 9,2 kOhms)
Auxiliary contacts (for signalling) all units 1 set changeover
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